Apparatus for making textured panels

ABSTRACT

This invention pertains to the method, and/or apparatus for rapidly producing the same so that fibrous board products including plywood panels would appear to simulate an adze surfaced product having a rustic appearance. The &#39;&#39;&#39;&#39;distressing&#39;&#39;&#39;&#39; or cutting of the product may be minimal or partial distressing or may be total distressing including overlapping cuts, or cuts within previous cuts.

O United States Patent [151 3,703,198

Luebs et al. 1 Nov. 21, 1972 [54] APPARATUS FOR MAKING TEXTURED [56] References Cited PANELS UNITED STATES PATENTS [72] Inventors: Donald F. Luebs, Vienna, Va.;

Frederick Ashby, Red Oak 585,886 7/1897 Lerch ..l44/l36 Ridge, NY. 3,234,978 2/1966 Stolensen et al. ......14 4/l36 R 1,629,742 5/1927 Scott ..l43/38 R X [73] Assgnee- 523 Imemmna' 857,738 6/1907 Karstens ..144/136 R [22] Filed: Feb. 25, 1971 Primary Examiner-Donald R. Schran [211 App. No; 118,665 AttorneyJames M. l-leilman and l-leilman & Heilman Related US. Application Data [57] ABSTRACT [62] Division of Ser. Nos. 759,624, Sept. 13, 1968, This invention pertains to the method, and/or apand Ser. No. 35,011, May 6, 1970, Pat. No. paratus for rapidly producing the same so that fibrous 3,616,826,and Ser. No. 118,666, May 6, 1970 board products including plywood panels would ap- V pear to simulate an ad ze surfaced product having a "144/2 144/136 32 9 2 rustic appearance. The distressing or cutting of the c Field of /l36 R, 3 R, 2 R, 2 D, 13, product may be minimal or partial distressing or may be total distressing including overlapping cuts, or cuts within previous cuts.

6 Claims, 6 Drawing Figures PAIENTED "UV 2 1 m2 SHEET 1 BF 2 INVENTORS DONALD F. LUEBS BY FREDERICK R. ASHBY ATTORNEY.

PATENTEU NOV 2 1 I972 sum 2 or 2 INVENTORS DONALD F. LUEB$ FREDERICK R. ASHBY ATTORNEY,

APPARATUS FOR MAKING TEXTURED PANELS RELATED APPLICATIONS This application is a division of parent application Ser. No. 759,624, filed Sept. 13, 1968, and copending applications Ser. No. 35,011, filed May 6, 1970, now US. Pat. No. 3,616,826, granted Nov. 2, 1971, and application Ser. No. 118,666, filed herewith, all of which are incorporated herein by reference, and all assigned to the same assignee hereof.

This invention pertains to a textured panel simulating preferably a rough hewn product, and the method, and apparatus for rapidly producing. the same so that the wood fiber boards including plywood panels would appear to simulate an adze surfaced product having a rustic appearance. The distressing or cutting of the product may be minimal or partial distressing or may be total distressing including overlapping cuts, or cuts in cuts.

The hand hewn effect is simulated by feeding plywood panels (which is understood to include all types of fibrous boards) longitudinally under transversely spaced rotary cutters having respective lifting mechanisms controlled by a programming device.

BACKGROUND There is a growing demand for textured panels having a surface effect simulating the rustic effect of the hand hewn appearance of old beams and old planks which were hewn out of logs by hand with an axe or adze.

This invention is applicable to any fibrous product, particularly of wood such as plywood, lumber, hardboard, particle board and the like, and has one of its most efiective uses in exterior plywood siding panels.

The number of cuts made in a panel or board may range from two to three cuts per square foot of surface area to cuts which cover the entire surface, and including double cuts in certain areas.

SUMMARY According to the present invention, an interior or exterior wood or plywood panel or siding to be textured is passed lengthwise with respect to transversely spaced tools stationed along the path of the panel. The tools are advanced intermittently toward the moving panel to distress spaced areas of the adjacent surface in a suitable pattern. Preferably the tools are rotated about transverse axes above the moving panel, and individually pneumatically, hydraulically, or electronically, advanced toward the moving panel. The advance of the tools toward the moving panel is preferably program controlled as, for example, by a program cylinder driven by the panel moving means.

DRAWINGS FIG. 1 is a plan view of a preferred embodiment of apparatus according to, and for carrying out the method of, the present invention;

FIG. 2 is a vertical longitudinal section taken along the line 2 2 ofFIG. 1;

FIG. 3 is a plan view of a plywood panel partially distressed by the invention;

FIG. 3A is a cross sectional view taken on the line 3A 3A of FIG. 3;

FIG. 4 is a partial plan view of a portion of a totally distressed panel; and

FIG. 5 is an enlarged longitudinal section taken on line 5 5 of FIG. 3 showing a five ply panel having the face veneer distressed by the invention.

DESCRIPTION OF ONE PREFERRED EMBODIMENT As shown in FIGS. 1 and 2, the machine comprises a bed 10 which supports a plywood panel workpiece 12 of 3, 5 or more plies, and having on each side a conveyor chain 14 driven through a common shaft by a conventional motor (not shown). The chain 14 is provided with dogs 16 for engaging the rear edge of the panel for feeding the panel along the bed 10 to pass under a transversely spaced series of cutting means, such as cutter heads 18. A fence 20 on each side of the bed 10 is adjustable for alignment of different widths of work.

The cutter heads 18, which may be of the same or different widths, are journaled on the ends of arms 22 pivoted on a drive shaft 24 driven by a motor 26. The cutter heads 18 are driven from the shaft 24 by belts not shown for sake of clarity. The arms 22 are connected to piston rods 28 for pneumatic cylinders 30, whereby the cutter heads 18 may be periodically lifted when so desired by a programmed cylinder 32 driven from the shaft 15 and connected to microswitches 34 operating through air lines 36 to actuate the pistons of the pneumatic cylinders 30. This mechanism may be, for example, similar to that of a player piano.

The operation, as the cutter heads descend (as shown in FIGS. 3, 4, and 5) these cutter heads gouge out areas 38 in the panel 12, which produce a textured appearance in the panel, simulating the adze marks in a hand hewn beam. The nature of the individual cuts in this process can be varied through several means. The length of the cut depends upon the time interval in which the cutter head is held in engagement against the panel, as well as the speed of the panel feed. The width is determined by the width of the knives in the cutter used, or the shape of the knives may be varied or they may be patterned to provide a textured cut. The transverse spacing of the cutter heads obviously may be varied. Certain of said cuts will be formed in the original surface of the panel sometimes leaving large areas uncut. Other cuts will be formed within and overlapping previous cut-out sections, i.e., cuts in cuts.

As mentioned above, the individual single cut-out portions may vary greatly depending upon individual preference; It has been found that k to 3 inches in length, preferably about 3, k to 3 inches in width, and 1/32 to 3/16 inches in depth, preferably about A; inches, to be particularly effective.

If desired, large flat panel may be grooved at regularly or irregularly spaced intervals as illustrated in FIG. 3A by grooves 39, or by V grooves 39' as illustrated in FIG. 4.

For the information of the Examiner, a representative advertisement of the new products (Oldbridge, trademark of assignee U.S. Plywood-Champion Papers Inc.) made by this invention is attached hereto as Exhibit F which illustrate more dramatically than the drawing the startling effects achieved by the invention either in the rough or with various appropriate stains and/or finishes applied thereto.

Also the tearout which occurs along the rear edge of the cut will vary somewhat depending on the characteristics of the wood. Furthermore, the multiple, rotating cutter heads as described up to this point may be substituted by ganged saw blades (similar to dado heads), rotating abrasive heads, or by fixed knives (scrapers) to be brought into engagement against the panel according to a predetermined pattern similar to that used with the cutter heads. Furthermore, a number of knives may be affixed in an elongated cutter head (similar to a planing machine) which would rotate to scoop or gouge out a pattern of cuts according to placement of the knives. Also, the simulated adze marks may be produced by the removal of material through sand blast or shot blast, with or without a stencil or mask, or by hot or cold embossing of the surface by hot or cold dies, rolls, of platens.

Preferably, a second, third or fourth series of distressing tools (not shown for sake of clarity), with different height of cutting edge to produce varying depth of cuts can be positioned along the face of the panel to make as many marks in the panel of whatever pattern desired. While most of the cuts will gouge out the wood, other cuts may be employed, alone or in combination with the gouges, which merely mark, compress, or slit the wood, said marks, compressed areas, and slitted areas being of various depth, length, and width suitable to produce the desired effect. Also to further randomize the pattern, if desired, the banks of cutter heads may be oscillated in a slight side to side motion.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. Apparatus for treating the surface of a wood panel to simulate a textured hand hewn effect which comprises:

a. means for passing the panel lengthwise with respect to a transverse cutting area; 7

b. a support shaft positioned transversely over the panel;

c. a plurality of rockable arms mounted on the support shaft;

d. a rigid cutting tool rotatably mounted on each of said arms with means for rotating the tools;

e. pneumatic means coupled to said arms for moving the arms toward or away from the panel surface;

f. and a program control means coupled to said pneumatic means for producing a predetermined pattern of gouged out areas in the panel surface.

2. Apparatus as claimed in claim 1 wherein said program means includes a rotatable cylinder containing raised portions and coupling means between the raised portions and the pneumatic means for controlling the arm positions.

3. Apparatus as claimed in claim 2 wherein the coupling means includes a valve for each arm, said valve operation responsive to the raised portions on the cylinder.

4. Apparatus as claimed in claim 2 wherein the coupling means includes an air line connected between the rotating cylinder and the pneumatic means.

5. Apparatus as claimed in claim 2 wherein said pneumatic means includes a piston within a cylinder.

6. Apparatus as claimed in claim 2 wherein said rigid cutting tool includes a cylindrical topl holder cou led to a rotatable stub shaft, and a plurality of rigid cu ting blades secured to the cylindrical surface. 

1. Apparatus for treating the surface of a wood panel to simulate a textured hand hewn effect which comprises: a. means for passing the panel lengthwise with respect to a transverse cutting area; b. a support shaft positioned transversely over the panel; c. a plurality of rockable arms mounted on the support shaft; d. a rigid cutting tool rotatably mounted on each of said arms with means for rotating the tools; e. pneumatic means coupled to said arms for moving the arms toward or away from the panel surface; f. and a program control means coupled to said pneumatic means for producing a predetermined pattern of gouged out areas in the panel surface.
 1. Apparatus for treating the surface of a wood panel to simulate a textured hand hewn effect which comprises: a. means for passing the panel lengthwise with respect to a transverse cutting area; b. a support shaft positioned transversely over the panel; c. a plurality of rockable arms mounted on the support shaft; d. a rigid cutting tool rotatably mounted on each of said arms with means for rotating the tools; e. pneumatic means coupled to said arms for moving the arms toward or away from the panel surface; f. and a program control means coupled to said pneumatic means for producing a predetermined pattern of gouged out areas in the panel surface.
 2. Apparatus as claimed in claim 1 wherein said program means includes a rotatable cylinder containing raised portions and coupling means between the raised portions and the pneumatic means for controlling the arm positions.
 3. Apparatus as claimed in claim 2 wherein the coupling means includes a valve for each arm, said valve operation responsive to the raised portions on the cylinder.
 4. Apparatus as claimed in claim 2 wherein the coupling means includes an air line connected between the rotating cylinder and the pneumatic means.
 5. Apparatus as claimed in claim 2 wherein said pneumatic means includes a piston within a cylinder. 